Lensless instrument cluster with integration of hard telltales and halo lighting providing a seamless display appearance

ABSTRACT

The invention is a robust lensless instrument cluster configured for installation in a vehicle. The instrument cluster comprises an outer case, a PCB and lighting structure, an inner frame, an optical bonding assembly, halo lighting portions, a seamless display comprising tell-tale indicators and gauges, and an outer visor. The instrument cluster further comprises a plurality of LEDs for compartmentalized and indirect lighting of the tell-tale indicators on the seamless display and the halo lighting portions around the edges of the seamless display. Because the instrument cluster is lensless and otherwise exposed to the environment, it comprises a seal system to prevent the ingress of water and dust into the interior components.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 63/040,242 filed on Jun. 17, 2020.

FIELD OF THE INVENTION

The present invention relates to instrument clusters in vehicles.

BACKGROUND OF THE INVENTION

A typical vehicle includes an instrument cluster that is provided infront of the driver. Typically, an instrument cluster includes variousgauges and separate warning indicators which are meant to provideimportant information to the driver regarding the current status of thevehicle. Examples of gauges included in an instrument cluster comprise aspeedometer and a tachometer, while examples of warning indicatorsincluded in an instrument cluster comprise a check engine light, an oillight, and a tire pressure light.

Warning indicators are often called “tell-tale” (“TT”) indicators.Unlike gauges which can be difficult to read and understand, TTs areeither on or off. When a TT is on, it is a tell-tale sign to the driverthat something, depending on which TT is on, is wrong with the vehicleor otherwise requires attention. While it may be difficult for somedrivers to appreciate that there is a problem with the vehicle bylooking at gauges of an instrument cluster, Ti lights are easy to detectwhen they illuminate.

Instrument clusters include lights and electronics. As such, instrumentclusters are typically provided behind a lens which shields and protectsthe instrument cluster from, for example, water, dust, and scratching.While providing a lens in front of an instrument cluster provides muchneeded protection, such a design is not as modern in appearance comparedto a design which omits a lens (i.e., a “lens-less” design). However,providing an instrument cluster without a lens is not feasible due tothe instrument panel including lights and electronics, and omitting thelens results in the instrument cluster being exposed to, for example,water, dust, and scratching that can adversely affect the operationand/or appearance of the instrument cluster. Lenses not only protect theinstrument cluster from, for example, water, dust, and scratching, butare also provided as being curved structures, thereby providinganti-glare/anti-reflection properties.

Modern vehicles have ambient lighting on the inside of the vehicle whichcan be adjusted. Most vehicles that include ambient lighting aredesigned such that the ambient lighting can be dimmed, and/or the colorof the lighting can be changed depending on the preference of thedriver. Such ambient lighting is not typically provided along the sidesof the instrument cluster.

SUMMARY OF THE DISCLOSURE

An embodiment of the present invention comprises an instrument clusterpreferably for a vehicle, where the instrument cluster is lens-less,robust, provides a large “seamless” display (seamless meaning a main,central display blends, appearance-wise, with adjacent TTs), andincludes highway assist halo lighting, preferably in the form ofmultiple color halo lighting, along the sides of the instrument cluster.The instrument cluster also encompasses a structural design that canprovide a stable display performance under different driving conditions.

Additionally, because the instrument cluster is lensless and exposed tothe environment in which it is installed, the cluster further comprisesa seal system to prevent the ingress of water and dust into theinstrument cluster, particularly a printed circuit board and lightingstructure provided therein.

A preferred embodiment of the present invention comprises:

-   -   a lensless instrument cluster configured for installation in a        user environment, the lensless instrument cluster comprising:        -   an outer case;        -   a printed circuit board and lighting structure assembly            connected to the outer case;        -   an inner frame connected to the printed circuit board and            lighting structure assembly;        -   an optical bonding assembly connected to the inner frame;        -   a halo lighting portion; and        -   a seamless display comprising:            -   a main display portion comprising a gauge;            -   a tell-tale surface comprising a tell-tale indicator;                and            -   an outermost surface that is in direct contact with the                user environment.

A second preferred embodiment of the present invention comprises:

-   -   an outer case comprising a heat sink;    -   a printed circuit board and lighting structure assembly        connected to the outer case and comprising:        -   a first light emitting diode configured to illuminate a            tell-tale indicator;        -   a second light emitting diode configured to illuminate a            halo lighting portion;    -   an inner frame connected to the printed circuit board and        lighting structure assembly;    -   an optical bonding assembly connected to the inner frame and        comprising:        -   a thin-film-transistor;        -   an in mold decorative layer; and        -   packing material;    -   the halo lighting portion; and    -   a seamless display comprising:        -   a main display portion; and        -   a tell-tale surface.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front view of an instrument cluster which is in accordancewith an embodiment of the present invention.

FIG. 2 is a perspective, partially exploded view of the instrumentcluster shown in FIG. 1.

FIG. 3 is a perspective, exploded view that is similar to FIG. 2, butwhich shows further explosion of certain components of the instrumentcluster.

FIG. 4 is a cross-sectional view of the instrument cluster shown in FIG.1, taken along line 4-4 of FIG. 1.

FIG. 5 is a cross-sectional view that shows an optically clear materialin the instrument cluster functioning to reduce reflection.

FIG. 6 is an enlarged view of a portion of that which is shown in FIG.4.

FIG. 7 is an enlarged view of a portion of FIG. 6, showing illuminationof a TT, specifically a light blocking feature which functions toprevent the light being cast from the LED from travelling directly tothe TT.

FIG. 8 shows one of the inner cases of the instrument cluster, andincludes an enlarged view of a portion thereof.

FIG. 9 is an enlarged view of a portion of FIG. 6, specifically one ofthe end portions thereof, showing how highway assist halo lighting isachieved.

DETAILED DESCRIPTION OF AN EMBODIMENT OF THE INVENTION

While the present invention may be susceptible to embodiment indifferent forms, there is described herein in detail, a specificembodiment with the understanding that the present disclosure is to beconsidered an exemplification of the principles of the invention, and isnot intended to limit the invention to that described herein.

FIG. 1 is a front view of an instrument cluster 10 which is inaccordance with an embodiment of the present invention. The instrumentcluster 10 is lens-less, robust, provides a large seamless display 12having an outermost surface, and includes ambient lighting, preferablyin the form of adjustable color halo lighting portion 14 along the sidesof the instrument cluster 10. As shown in FIG. 1, the instrument cluster10 preferably displays one or more gauges or meters 16, and includestell-tale indicators (TTs) 18 that may or may not illuminate dependingon the current state of the vehicle. Examples of TTs 18 include but arenot limited to turn signal symbols, check engine symbols, and high beamsymbols. The gauges 16 and the TTs 18, collectively, appear (to thedriver) to all be part of the large, seamless display 12. Preferably,the instrument cluster 10 comprises tell-tale surface 20 (and alsoin-mold decorating (“IMD”) surface 58) through which the TTs 18 areviewed to provide a seamless stylish, floating look, i.e., compared to amain display section or portion 22 that provides the gauges or meters16. As shown in FIG. 1, borders 21 are shown to delineate tell-talesurface 20 from main display portion 22, whereas in practice the borders21 are preferably imperceptible to a user. This is a feature of the“seamless” display 12. In preferred embodiments, the TTs 18 areimpregnated on surface 58 (see FIGS. 4-7, 9). As will be appreciated bythose of skill in the art, the orientation, size, color, format, andtype of gauges 16 and TTs 18 displayed by the cluster 10 may vary.

The instrument cluster 10, when fully assembled and installed in avehicle, preferably provides structural integrity, specifically dynamicperformance regarding, for example, mechanical shock and vibration withthermal shock. The instrument cluster 10 is also preferably configuredto resist the entry of water and dust, as will be described in moredetail later hereinbelow.

FIG. 2 is a perspective, partially exploded view of the instrumentcluster 10 shown in FIG. 1, while FIG. 3 is a similar view, but showsfurther explosion of certain components of the instrument cluster 10.FIG. 4 is a cross-sectional view.

As shown in FIGS. 2 and 4, the instrument cluster 10 preferablycomprises a printed circuit board (“PCB”) and lighting structureassembly 24 that is mounted in an outer case or housing 26. As shown inFIGS. 2 and 3, an optional speaker 28 is disposed in the PCB andlighting structure assembly 24. As shown in FIG. 2-4, the instrumentcluster 10 also includes one or more heat sinks 30 (preferably one, asshown), an optical bonding assembly 32, an inner frame 34, and an outervisor 36. Preferably, the heat sink 30 is comprised of aluminum or someother suitable material(s). Preferably, the outer case 26, the innerframe 34, and the outer visor 36 are formed of a polymer such asplastic. Preferably, the inner frame 34 provides reinforced ribs 38 (seeFIG. 4) such as at locations of interface with other components of theinstrument cluster 10.

As shown in FIGS. 3 and 4, the PCB and lighting structure assembly 24preferably comprises a PCB assembly 40 as well as (one on each side ofthe PCB and lighting structure assembly 24): inner visors 42, halodiffusers 44, and light guides 46, as well as an inner case 48 that isformed of similar pieces on each side of the instrument cluster 10.Preferably, each of the inner visors 42, halo diffusers 44, light guides46, and the inner case 48 (both components) is formed of plastic, andthe PCB 40 includes LED's thereon for illumination of both TTs 18 andhalo lighting 14 (see FIG. 1).

Regarding the optical bonding assembly 32, preferably the opticalbonding assembly 32 comprises a thin-film-transistor (“TFT”) 50, an inmold decorative lens or layer 52, and packing material 54, which ispreferably a packing foam. Preferably, the instrument cluster 10 is heldtogether using a plurality of fasteners 56 (the fasteners appear only inFIG. 3).

Preferably, the instrument cluster 10 is lens-less in that theinstrument cluster 10 is not set back a distance from a curved lens thatprotects the instrument cluster 10. Instead, preferably the instrumentcluster 10 is exposed and is touchable. Therefore, the instrumentcluster 10 preferably includes the in mold decorative lens 52, and thein mold decorative lens 52 is preferably hard, resists scratching, ischemically resistant, and is configured to provideanti-glare/anti-reflection properties. Preferably, the in molddecorative lens 52 has a smoke tint. More specifically, preferably thein mold decorative lens 52 comprises a resin at its core, preferably apolymethyl methacrylate (“PMMA”) surface 58, and has an opaque blackprinting or coating 60 on its outside surface (i.e., the surface facingthe driver of the vehicle). Preferably, the resin 58 provides a 65%smoke tint while the coating 60 on the resin 58 provides a 15% smoketint. The coating 60 provides the in mold decorative lens 52 with ablack background area through which the TFT 50 can be viewed. Thetinting design helps to provide the seamless appearance between thetell-tale surface 20 and the main display portion 22 at the borders 21.Regarding hardness, preferably the in mold decorative lens 52 providesan at least 2H level of hardness as a result of the hard coat layer 60and the resin 58, wherein the in mold decorative lens 52 resistsscratching and can be wiped clean and/or dry using a napkin or cloth.

As shown in FIG. 5, preferably instead of an air gap being providedbetween the in mold decorative lens 52 and the TFT 50, an opticallyclear material 62 is provided on the mold decorative lens 52, adjacentthe TFT 50. The optically clear material 62 provides less refection ofsunlight as well as less reflection of light that emanates from the TFT50 compared to if an air gap were provided. The use of optically clearmaterial 62 provides that the image being displayed on the TFT 50 isvisually transposed up to the outer surface 60 of the in mold decorativelens 52. In other words, the perception of the display of the TFT 50being lower than the in mold decorative lens 52 is lost. This visualperception results because there is no substantial change of mediumbetween the TFT 50 and the in mold decorative lens 52. The combinationof the coating 60 on the one side of the in mold decorative lens 52 andthe optically clear material 62 on the opposite side of the in molddecorative lens 52 provides an anti-glare feature resulting in increasedreadability due to the reduction of sunlight reflection, and increasedimage brightness due to higher light efficiency.

As shown in FIG. 6, the instrument cluster 10 comprises a seal system toprevent the ingression of water and dust, especially toward the PCB andlighting structure assembly 24 and the optical bonding assembly 32(which includes the TFT 50). This seal is provided as a result of thepacking foam 54 being disposed between the in mold decorative lens 52and each inner case component 48 (only one is shown in FIG. 6), andfurther sealing of the overall structure is provided as result of theabutment of different surfaces of the components shown in FIG. 6. Forexample, preferably there is a flange 64 proximate each end the innervisor 42 which engages a corresponding flange 66 on the outer case 26 toprevent entry of water, etc.

With regard to the packing foam 54, preferably water sealing foam thathas a compression hardness of 0.25N/cm2 for 50% compression is used suchthat the total force acting on the in mold decorative lens 52 is around6.3N which is negligible compared to the optical bonding force.Preferably, packing foam 54 is applied between the inner case 48 and thein mold decorative lens 52 between each TT 18, to prevent light leakage(i.e., to provide light meant to illuminate one TT from casting intoanother, adjacent TT).

In addition to the sealing, the instrument cluster 10 preferably has adrain hole design allowing moisture to escape from the overall assembly.Further to that end, as shown in FIG. 4, preferably the outer case 26includes internal flanges 68 which tend to direct water down into drainholes (represented with reference numeral 70 in FIG. 4) for escape fromthe overall assembly.

As also shown in FIG. 6, the PCB provides LED's 72 (only one is shown inFIG. 6) that illuminate to provide lighting through a TT image 18 (inthe form of a cut out in the printing or coating 60 on the outsidesurface of the in mold decorative lens 52). As shown in more detail inFIG. 7, preferably the inner case 48 provides a light blocking feature,such as light cup 75 comprising a rib 76 and conical portion 78, whichfunctions to prevent the light being cast from the LED 72 fromtravelling directly to the TT 18. Instead, the illumination is dispersedgenerally over a larger area, an area that includes the TT 18, therebypreventing a hot spot that would otherwise appear in the TT 18.Preferably, a back side of the in mold decorative lens 52 includestextured surface 81 that also tends to eliminate any perceived hotspotting in the TT 18. As shown in FIG. 7, the conical portion 78extends from walls 77 toward LED 72 at a preferably 35 degree angle.Terminal portion 79 of the conical portion 78 defines an opening 73 thatis preferably 4.2 millimeters in diameter. FIG. 8 shows one of the innercase components 48 of the instrument cluster 10, and shows a portionthereof enlarged so the light cup 75 can be readily seen. As shown, therib 76 preferably extends horizontally from the terminal portion 79toward a center of the opening 73.

The TFT 50 could be, for example, a large, 10.25-inch-wide display. Aswill be appreciated by those of skill in the art, other widths anddimensions are contemplated for the purpose of adaptation and fit tospecific uses. This display is seamless relative to TTs 18 (that may ormay not illuminate depending on the current state of the vehicle).Preferably, the contrast difference between the display emanating fromthe TFT 50 and the illuminated TTs 18 is minimal and the illuminationperformance is similar.

With regard to the halo lighting 14 that is preferably provided on bothsides of the instrument cluster 10, preferably the halo lighting 14provides red-blue-green (“RGB”) color capability and is configured to beadjusted with regard to not only the color, but also intensity andpropagation. The halo lighting 14 may be configured to provide a highwaypilot lighting mode for vehicles that have autonomous driving. Halolighting 14 may also provide ambient lighting for aesthetic purposes,such as an orange halo illumination. As shown in FIG. 1, the halolighting 14 may generally propagate in a generally c-shaped or curvedconfiguration around each side of cluster 10. It is contemplated thatother propagation configurations and shapes for halo lighting 14 may bedeployed in alternative clusters 10.

FIG. 9 provides an enlarged cross-sectional view of one of the endportions of the instrument cluster 10, showing how halo lighting 14 isachieved on each side of the instrument cluster 10. Preferably, halolighting 14 is achieved via light channeling. As shown, preferably thelight guide 46 is disposed over one or more LED's 74 of the PCB 40 suchthat light emitted from the one or more LED's 74 is directed toward theinner visor 42 (i.e., on path 84) which preferably has a curved surface80 which disperses the light along the edge of the instrument cluster10. To provide a desired level of fading propagation for the halolighting 14, a specific sized gap 82 between the inner case 48 and theinner visor 42 can be selected. In preferred embodiments, the gap 82width is between 2.0 to 5.0 millimeters. Additionally, the width of gap82 may be tapered. For example, the gap 82 width may increase as itextends from a top edge of display 12 toward an outer edge of display 12to provide a smooth transition from bright to dark portions of the halolighting 14. The combination of the profile of the light guide 46 andthe curvature of the inner visor 42 works to achieve uniform halopropagation. Halo lighting 14 is preferably employed on both sides ofthe instrument cluster 10, and is preferably adjustable regarding colorand intensity. As such, preferably the instrument cluster 10 provides anintegrated package wherein a single PCB 40 provides both hard TT LED'sand halo illumination via a plurality of LED's 72, 74.

The instrument cluster 10 provides a lens-less, seamless design, whereinTTs 18 and a main display 22 are effectively integrated using,preferably, a single PCB 40. The instrument cluster 10 is robust, isdesigned to provide anti-glare properties, and its internal componentsare effectively sealed from water and dust. The outer surface provideshardness yet resists scratching and can be wiped clean/dry using anapkin or cloth. The instrument cluster 10 provides attractive,preferably adjustable, halo lighting 14.

As defined herein, the “outermost surface” of display 12 designates thesurface of the display 12 that is directly exposed to an externalenvironment and capable of being directly contacted by a user duringnormal operation. For example, the external environment may be a userenvironment where the instrument cluster 10 is installed, such as thecabin of a vehicle. Preferred embodiments of display 12 comprise in molddecorative lens or layer 52 having coating 60 as the outermost surface.This is just one example of a preferred embodiment, and one of ordinaryskill in the art will appreciate that the outermost surface is dependenton the preferred composition of the display 12.

As defined herein, “lens-less” refers to the absence of a protectivecover or shield found in traditional instrument clusters. In traditionalsystems, the protective shield and the display surface of the clusterdefine a void between the shield and the display surface. There is nosuch void defined by preferred embodiments of the present invention. Asdescribed herein, the in mold decorative “lens” 52 is preferablyintegral with the display 12.

While a specific embodiment of the invention has been shown anddescribed, it is envisioned that those skilled in the art may devisevarious modifications without departing from the spirit and scope of thepresent invention.

The invention claimed is:
 1. A lensless instrument cluster configuredfor installation in a user environment, the lensless instrument clustercomprising: an outer case; a printed circuit board and lightingstructure assembly connected to the outer case; an inner frame connectedto the printed circuit board and lighting structure assembly; an opticalbonding assembly connected to the inner frame; a halo lighting portion;and a seamless display comprising: a main display portion comprising agauge; a tell-tale surface comprising a tell-tale indicator; and anoutermost surface that is in direct contact with the user environment.2. The lensless instrument cluster of claim 1, further comprising anouter visor connected to the optical bonding assembly.
 3. The lenslessinstrument cluster of claim 1, wherein the printed circuit board andlighting structure assembly comprises a first light emitting diodeconfigured to illuminate the tell-tale indicator and a second lightemitting diode configured to illuminate the halo lighting portion. 4.The lensless instrument cluster of claim 3, wherein the optical bondingassembly comprises a thin-film-transistor, an in mold decorative layer,and packing foam.
 5. The lensless instrument cluster of claim 1, whereinthe printed circuit board and lighting structure assembly comprises aninner case and a light emitting diode configured to illuminate thetell-tale indicator, and wherein the inner case comprises a lightblocking feature that is configured to provide an indirect illuminationof the tell-tale indicator by the light emitting diode.
 6. The lenslessinstrument cluster of claim 5, wherein the light blocking feature is alight cup.
 7. The lensless instrument cluster of claim 6, wherein thelight cup comprises a conical portion, a rib, and a textured surface. 8.The lensless instrument cluster of claim 1, wherein the printed circuitboard and lighting structure assembly comprises an inner visor, a lightguide, and a light emitting diode configured to illuminate the halolighting portion, wherein the light guide is disposed over the lightemitting diode such that light emitted from the light emitting diode isdirected on a path toward the inner visor.
 9. The lensless instrumentcluster of claim 8, wherein the printed circuit board and lightingstructure assembly further comprises an inner case, wherein the innervisor has a curved surface, and wherein the inner case and the innervisor define a gap having a width.
 10. The lensless instrument clusterof claim 9, wherein the width of the gap is tapered.
 11. A lenslessinstrument cluster comprising: an outer case comprising a heat sink; aprinted circuit board and lighting structure assembly connected to theouter case and comprising: a first light emitting diode configured toilluminate a tell-tale indicator; a second light emitting diodeconfigured to illuminate a halo lighting portion; an inner frameconnected to the printed circuit board and lighting structure assembly;an optical bonding assembly connected to the inner frame and comprising:a thin-film-transistor; an in mold decorative layer; and packingmaterial; the halo lighting portion; and a seamless display comprising:a main display portion; and a tell-tale surface.
 12. The lenslessinstrument cluster of claim 11, wherein the printed circuit board andlighting structure assembly further comprises an inner case comprising alight blocking feature that is configured to provide an indirectillumination of the tell-tale indicator by the first light emittingdiode.
 13. The lensless instrument cluster of claim 12, wherein thelight blocking feature is a light cup comprising a conical portion, arib, and a textured surface.
 14. The lensless instrument cluster ofclaim 11, wherein the printed circuit board and lighting structureassembly further comprises an inner visor and a light guide, wherein thelight guide is disposed over the second light emitting diode such thatlight emitted from the second light emitting diode is directed on a pathtoward the inner visor, thereby providing an indirect light at the halolighting portion.
 15. The lensless instrument cluster of claim 14,wherein the printed circuit board and lighting structure assemblyfurther comprises an inner case, wherein the inner visor has a curvedsurface, and wherein the inner case and the inner visor define a gaphaving a tapered width.
 16. The lensless instrument cluster of claim 11,wherein the tell-tale surface comprises a plurality of tell-taleindicators, wherein printed circuit board and lighting structureassembly further comprises an inner case, and wherein the packingmaterial is disposed between the in mold decorative lens and the innercase between each of the plurality of tell-tale indicators to preventlight cast by the first light emitting diode from illuminating more thanone of the plurality of tell-tale indicators.
 17. The lenslessinstrument cluster of claim 11, wherein the lensless instrument clusteris configured for installation in a user environment, and the seamlessdisplay further comprises an outermost surface that is in direct contactwith the user environment.
 18. The lensless instrument cluster of claim17, wherein the printed circuit board and lighting structure assemblyfurther comprises an inner case and an inner visor, and wherein lenslessinstrument cluster comprises a seal system to prevent the ingress ofwater and dust into printed circuit board and lighting structure, theseal system comprising: the packing material being disposed between thein mold decorative lens and the inner case; a first flange disposed onthe inner visor that is correspondingly engaged with a second flangedisposed on the outer case; and a third flange disposed on the outercase that directs water into a drain hole defined by the outer case.